RvLock Atlas
ABOUT
Atlas V1 was losing market share — existing door cutout configurations left a significant portion of RV owners unable to install the handle.
The Atlas redesign addressed this directly: a patent-pending linkage locking system and Multi-Fit Adapter that expanded fitment to cover the full range of RV door configurations from a single SKU. Locking strength increased from 66 lbf to 500 lbf. Developed through to production.
I led 3D CAD surfacing, mechanical design, FEA, and testing validation end to end.
YEAR:
2024-2025
ROLE:
Industrial Design, Design Engineering
PROCESS
THE PROBLEM
Atlas V1 was generating customer complaints and missing a significant share of the market due to limited door cutout compatibility. The redesign had two mandates: solve the fitment problem and dramatically improve locking strength.
Atlas V1 (left) vs Atlas V2 (right)
LINKAGE BAR LOCKING SYSTEM
US20250109617A1
The locking system was redesigned around a linkage bar mechanism that locks the deadbolt and paddle simultaneously — improving security and simplifying internal assembly.
Linkage bar locks deadbolt and paddle in a single motion
LOCKING PIN GEOMETRY
FEA
Early iterations used flat-face-to-flat-face contact geometry. FEA revealed stress concentrations at the interface driving failure at 66 lbf. Pins were redesigned with an 11-degree angled contact face, distributing load into the exterior casting.
Early concept (left) showing stress concentrations exceeding yield strength. Optimized geometry (right) dispersing stress across the assembly.
MULTI -FIT ADAPTER
US20250109619A1
A sheet metal subassembly with a swappable deadbolt in two lengths. Option A for cutouts offset from the door edge. Option B for cutouts at the edge. All configurations modeled as Onshape assemblies for rapid switching.
Onshape assembly configurations and motion simulation.
INDUSTRIAL DESIGN
A new bevel was developed to modernize the handle silhouette, improve grip ergonomics, and unify the aesthetic across RVLock's product line.
Linkage bar locks deadbolt and paddle in a single motion
RESULTS
With the Multi-Fit Adapter, RVLock could serve the full addressable market for the first time — capturing previously inaccessible customer segments. Amazon sales doubled and website sales increased 20%
The Atlas shipped as the first handle of its style in the category. Locking strength reached 500 lbf — a 7.5x improvement over the original 66 lbf — validated using a custom tensile test frame I designed and built in-house, fitted with a load cell to measure pull force directly on the mechanism. Results confirmed across multiple production samples.
Two patents were filed covering the work: US20250109617A1 — linkage bar locking system US20250109619A1 — Multi-Fit Adapter mechanism
REVIEWS
"The new lock was easy to install. It fits beautifully and looks like it belongs there from the factory. No more need to carry a key when leaving the rig. No more I forgot to bring the key with me. Love the new lock!"
John S.
Verified Customer
